The Réplic’Air Association goals are to re build old aircrafts and to make them fly again. The last project carried out by the association was to re build the Type G Morane Saulnier in order to cross the Mediterranean sea. On this aircraft, about 15 parts were 3D printed. The new project launched by the association is to re build the Dewoitine D551. For this aicraft, more than 30 parts have been selected and will be 3d printed. Assystem Technologies as the main partner of the project will show how the parts have been selected by focusing on the main criteria used, the re design works carried out in collaboration with Prismadd and the difficulties faced. Assystem Technologies will also present how the cooperation has been managed with Réplic’Air and Prismadd.

The qualification of powder bed fusion processes is based on lengthy and expensive experimental trial and error. If models can be applied to predict process details and determine the probability of manufacturing defects, the qualification process could be accelerated and cost can be reduced significantly. This paper describes numerical results resolving powder bed fusion processes and defects that could potentially happen during manufacturing. A multi-physics and multiscale modelling platform is first introduced in section 1 before proceeding to present numerical results of several defects that have been observed experimentally.